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Art of Constructing Premium Cigars

Not only is the choice of tobacco essential, but the placement of the different types of tobacco becomes very important. You can readily tell the difference of a premium cigar by trying a taste of the various tobacco as a standalone cigar when you join us in our blending room at Doña Elba.

The construction of a premium cigar at Doan Elba Cigar goes through testing for the draw. We start with the formula that tells the buncher exactly how much of each tobacco to include in each premium cigar. The method also shows where the different types of tobacco are placed, whether it is in the first third, middle third, the bottom third, or the entire length of the premium cigar at Doña Elba. When multiple fillers are used, our formula designates where each type of leaf is placed in the binder.

We also run each of the cigars, after pressing but before the Capa (Wrapper) through our draw machine. A cigar that fails is returned to the roller and later used in our cigarillo product.

Under Filled Cigars

An underfilled cigar is constructed by skimping on the number of leaves in the filler. The draw will be smooth, and the burn will hot burning and harsh underfilled leaves too many air pockets.

Overfilled Cigars

A cigar that is overfilled will undoubtedly be hard to draw. Sometimes they are called plugged cigars. A hard to draw cigar gives much less volume of smoke, giving less taste and aroma. There is no excuse for this overfilled cigar when a Doña Elba Cigar formula is followed by the buncher and roller.

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